Apparatus for folding a paper strip into a yarn



y 1965 c. e. EVANS ETAL 3, 0

APPARATUS FOR FOLDING A PAPER STRIP INTO A YARN Filed March 11, 1965 FIG.-l-

INVENTORS OYRILG.EVAN$ BOBBY L. PITTS- WILLIAM RWARTHEN ATTORNEY United States Patent 3,l%,9tl i ilPAf-EATUS FER SJILDENG A PAPER Slfllll ENTQ A YARN Cyril G. Evans, Bobby L. Pitts, and William P. Warthen,

Spartanburg, S,C., assignors to Deer-Eng lililiilren Research tjorporation, Spartanhurg, S.C., a corporation of Delaware Filed Mar. 11, 1963, her. No. 264,375 (Zlaims. (6i. 28-4) cause of tie friction and resulting tensions developed in these systems. Also, such systems do not produce a highly uniform yarn.

Accordingly, it is an object of this invention to provide novel apparatus and methods for producing flat, folded twistless paper yarn which has one or more of the advantages of lower processing tensions, higher production speed capacities and more uniform yarn production.

Another object is to provide such an apparatus which is compact and inexpensive to produce.

On or objects will be apparent to those skilled in the art to which this invention pertains.

According to this invention, a continuous paper strip is taken from a supply roll and passed into a shaping zone which causes the edges of the paper strip to curve toward each other, and then passed in an arcuate path, convex with respect to the curved edge portions, under tension whereby the curved edge portions are drawn tightly against the center portion of the paper strip, thereby folding the paper strip. The folded strip is then preferably passed through a constricted zone which creases the folds. Preferably also the folded paper strip is passed through two shaping zones and arcuate paths which consecutively impart a multiplicity of folds t0 the paper strips. Preferably also the folded strip is creased a multiplicity of times the transverse direction to impart a crimped configuration to the yarn.

Apparatus suitable for performing the folding process comprises one or more guides to guide the paper strip a partial wrap around a rotatable roll and into a flat bottomed groove in the roll of a width such that one or both of the edge portions of the paper strip must fold inwardly upon the central portion of the strip for the strip to fit into the groove. Means are provided to impart sufficient tension to the paper strip so that the strip is urged to enter and remain in the groove. Because the strip is passed in an arcuate path while the edge portions are turned inwardly, the strip assumes a folded connguration, with a sufificiently sharp crease at the edge of the fold so that the strip retains the folded configuration upon leaving the groove. A pair of nip rolls are, however, generally provided to further crease the folded paper strip. In a preferred apparatus two such grooved rolls are provided in sequence so that the once folded strip is again subjected to another folding operation. In such an arrangement, the nip rolls will follow both grooved rolls.

This invention is illustrated and exemplified in the drawings in which,

FIGURE 1 is a schematic perspective view of an apparatus of this invention;

FIGURE 2 is an enlarged fragmentary planar view of a supply roll guide roll of an apparatus of this invention;

assess.

Patented July 13, E855 FiGURES 3 and 4 are enlarged planar views of the forming wheel and the first folding wheel of the apparatus of FIGURE 1; and

FIGURES 5a and 5b are fragmentary planar views of alternate means for folding a paper strip employing pairs of folding wheels.

In the embodim nt shown in FIG. 1, a supply roll lltl of paper strip is supported along its periphery by guide rolls 12, 14, 16 and 18. As shown more clearly in MG. 2, these supply r-oll guide rolls have annular peripheral grooves it, with tapered sides 22a and 22b, of dimensions such that the top of groove 2:; is wider and the bottom 24 of the groove 2% is narrower than the width of supply roll it). Thus, the sides 22a and 22b of the groove 2% present an acute angle to the respective sides of the supply roll 10. This angle desirably is about 5 to 25,

more preferably about 10 to 20. These tapered sides provide gripping surfaces for the edges of the outermost several layers of the paper strip on the supply roll, thus keeping these outer layers tightly wound as this supply roll unwinds and preventing the supply roll from walking out of the guide rolls during high speed operations. The top two guide rolls 12 and 14 are slidably mounted by an assembly 26 on shafts 28a and 28b so that as the supply roll It? is consumed (as shown in phantom in FIG. 1), peripheral contact with the supply roll is maintained by upper supply roll guide rolls 12 and 1d. The guide roll mountings 26 can be arranged to receive weights to provide the desired degree of tension in the folding system. Also, the shafts 28a and 28b can be curved so that a constant force is exerted on the supply rolls by the upper guide rolls 12 and 14 as the roll unwinds,

The paper strip 3A) is unwound from the supply roll it optionally passed around a guide roll 35, through a guide trough 37 and under guide roll 39, and then tangentially contacted with one or more forming rolls 41 having a round bottomed annular peripheral groove d3 which causes the paper strip to assume a U-shaped configuration, as also shown in FIG. 3. The U-shaped paper strip is then passed directly a partial wrap around folding roll 56 in its annular peripheral groove 52 as shown in FIG. 4. This partial wrap under tension causes the folded edge portions 319a and Bill) to be pressed tightly against the central portion Si o, thus causing the edges Etta and Site of the folded paper Sill to be creased. The sides 52a and 52b of the groove 52 act as final guides for the U-shaped paper strip, the distance therebetween, i.e., the width of the groove, determining the width of the folded edge panel portions 3% and 3%. As shown in FIGS. 5a and 5b, the width of the groove 52 can be such that the edge panel portions 349a and 3% are in contiguous parallel (PEG. 5a) proximate parallel (FIG. 515) or overlapping parallel (not shown) folded relationship.

The folded paper strip oil is again passed a partial wrap around a further grooved folding roll 62 in its annular fiat bottomed peripheral groove 64; to again fold the paper strip so. As shown in FIG. 511, if the second folding roll 62 is oifset with respect to the first folding roll Stl, the folded paper strip 6:) will fold approximately along its longitudinal center to bring folded edge panel portions Fitla and Stlb into face-to-face contact. If the second folding roll 52 is positioned in line with the first folding roll Stl, as shown in FIG. 5b, the folded paper strip will fold about in the longitudinal center of the panel portions Etta and 3% so that they fold upon themselves. With such a folding arrangement, the twice folded paper strip 7% is preferably thereafter again folded, this time along its longitudinal center.

A guiding wheel 66 is preferably provided between folding rolls 5t and 62 to assist in the second folding operation and to ensure that the folded edge panel portions 7 limited solely by the appended claims.

a 3 30a and 3% do not unfold asthe paper strip 60 is urged into its second folded configuration 7tla.

The twice folded paper strip 70a or 76b is then passed through a pair of nip rolls 72 and '74 to crease the final folds and finally through partiallymeshing gears 76 and 73, one or both of which are driven by means not shown, to draw the paper strip through the folding apparatus, thus imparting a multiplicity of transverse edge-to-edge creases in the final folded paper yarn 80. Only the nip rolls 72 and '74 or the gears 76 and 78, rather than both, need be employed to crease and stabilize'the folded yarn.

groove in its peripheral surface to shape the unfolded paper strip intoa substantially U-shaped configuration, a

' second rotatably mounted roll having a fiat bottomed an- Any or all of rolls 35, 41, 56, 62, 72, '74, 76 and 73. 3

can be driven to assist the paper strip through the folding apparatus or to vary the tension in the system. However,

speeds in excess of 1,000 yards per minute can be achieved with only gears 76 and 7 8 being driven. Thus, in the preferred modification, gears 76 and 78 are driven, guide .7

wheel 66 is stationary, wheel 5% is friction rotatably mounted to provide added tension in the system and all other wheels are idler wheels. l 1

The folded paper yarn 8% can be taken up in any suitable manner, For example, it can be. passed in a random manner into a can, or transverse cone wound or surface wound in the manner of a Barber-Coleman winder. Also,

the yarn can be passed directly into the feed of a knitting,-

'multiplicity of ends of the final folded yarn is joined to the starting roll of unslit paper. i

The paper strip used in the apparatus and method of this inventionpreferably is the so-called slitting grade kraft, e.g., of a weight of 5 to 35 and even up to 50 or higher lbs./ ream. The strip is preferably about A" wide but can vary from about' Ad'to /;z. Other papers, with and without wet strength, varying from tissue and onion skin types to rag content bond can also be usedr It is desirable, and sometimes necessary when using wet strength paper or paper of l0or more pounds per ream weight, that the paper strip be moist during the formation into yarn. Moisture sufiicient to impart a slightly damp but not a wet feel to the paper is ideal and can be obtained by conditioning the paper in a high humidity atmosphere prior to the forming operation. Paper having a high degree of longitudinal fiber orientation is also a desirable paper to use. If the paper is in the form of a pancake package, this conditioning can also be achieved by immersing at least the edge portions of the package for a few moments in water, which preferably contains a lubricant such as emulsified polyethylene, or by spraying the edges, and then storing the package for at least several hours in a sealed container, e.g., a polyethylenebag, prior to use to permit the moistureto distribute its-elf evenly throughout the package. Spraying is preferred for the lighter weight, e.g., 5 lbs/ream, papers.

When the forming operation in which the paper strip is formed into folded yarn is made an integral part of the nular groove therein with a width less than the unfolded Width of the paper strip, guide means to continuously supply said paper strip to said first roll to shape said paper strip into a subtsantiallyiU-shaped configuration and then to guide-the paper strip a partial wrap around said second roll, tension means to draw the substantially U-shaped paper strip firmly into the bottom of the groove in said second roll, thereby causing the edges of the paper strip to fold inwardly toward each other on the same side of the paper strip as the paperstrip takes the partial wrap around said second roll, and means to crease the paper strip in its folded configuration.

2. Apparatus according to claim 1 including an additional rotatable roll, following the roll having the flat bottomed groove around which the folded paper strip slitting operation, the paper can be moistened before slitting or after, avoidingsuch eXc-essivemoistening as would cause excessive weakening of the paper. The yarns of this invention are useful in preparing knitand woven fabrics, e.g., those'claimed in application Ser. No. 219,875, filed August 28, 1962, now abandoned.

It will be apparent that various modifications within' the contemplation of this invention will be apparent to 7 those skilled in the art and this invention What is claimed is: I 1. Apparatus for continuously forming fiat, twistless is' therefore takes a partial wrap, havinga first transverse portion of greater diameter than a second transverse portion to provide a shoulder therebetween, which shoulder provides a guide surface which causes the folded paper yarn to again fold upon itself.

3. Apparatus according to claim 2 wherein the shoulder positioned with respect'to the path. of the folded yarn leaving the roll having the flat bottomed groove so as to 'cause the yarn to fold upon itself substantially along its longitudinal center.

4. Apparatus according to claim 2 including guide means positioned between the rotatable roll having the flat bottomed groove and the additional rotatable roll urging the folded paper strip to retain its existing folds while again folding upon itself.

5. Apparatus according to claim 1 wherein the means to crease the paper comprise a pair of at least partially intermeshing gears which also transversely crease the folded paper strip to impart a crimped configuration thereto.

6. Apparatu according to claim 1, comprising means for rotatably and vertically mounting a supply roll of paper strip for tangential unwinding, including a plurality of rotatable rolls for supporting and guiding the supply roll at spaced apart points along its periphery.

7. Apparatus for continuously forming flat, twistless folded paper yarn from a paper strip comprising: first and second rot-atably mounted rolls, guide means, including a guide roll-to continuously shape the unfolded paper strip into a substantially U-shaped configuration, to guide the paper strip consecutively a partial wrap around said first and second rolls, said first and second rolls each having a-fiatbottomed annular groove in the peripheral surface ofthe roll of a width less than Width of the paper 'strip prior to taking the partial wrap therearound, tension means to draw the U-s'haped paper strip firmly into the bottom of the groove of the first rotatable roll, thereby causing the edges of the paper strip to fold inwardly toward each other on the same side of the paper strip as the paper strip takes the partial wrap around the first rotatable roll, and to draw the thus folded paper strip firmly into the bottom of the groove of the second rotatable roll thereby causing the folded paper strip to again fold while taking the partial'wrap around the second rotatable roll, guide means positioned between'said first and second rotatablerolls urging the folded paper strip to retain its existing folds while again folding upon itself, and means to crease the foldsin the folded paper strip. 7

8. Apparatus according to claim 7 wherein the groove of the second rotatable roll is positioned with respect to the path of the folded paper yarn such that one side of yarn to fold substantially along its longitudinal center bringingthe folded edge portions thereof into contiguous relationship. 1 a

9. Apparatus according to claim 7, comprising means .for rotatably and vertically mounting a supply roll of paper strip for tangential unwinding, including a plurality of rotatable rolls for supporting and guiding the supply roll at spaced apart points along its periphery.

10. Apparatus according to claim 9 wherein the supporting and guiding rotatable roll each have an annular groove with tapered walls in its peripheral surface of a Width at the surface of the roll greater than the width of the paper strip and narrower than the paper strip at the bottom of the groove so that the rotatable rolls engage the supply roll by the edges of the most outwardly positioned layers of the paper strip forming the roll, thereby also holding the outer layers of the supply roll in alignment with the supply roll as the supply roll rotates.

11. Apparatus according to claim 9 wherein at least one of the supporting and guiding rotatable rolls is positioned so as to engage the upper portion of the roll of paper and is slidably mounted so as to maintain peripheral contact with the roll of paper as it diminishes in size upon unwinding.

12. Apparatus according to claim 11 wherein the upper portion engaging supporting and guiding roll is weighted to produce the desired degree of tension in the paper strip during the folding operation.

13. Apparatus for continuously forming flat, twistless folded paper yarn from a paper strip comprising: a supply roll of paper strip, means rotatably and vertically mounting said supply roll of paper strip for tangential unwinding, said means including a plurality of rotatable rolls for supporting and guiding said supply roll at spaced points along its periphery, said supporting and guiding rolls each having an annular groove with tapered walls in its peripheral surface of a width at the surface of the roll greater than the Width of the paper strip and narrower than the paper strip at the bottom of the groove so that the rotatable rolls engage the supply roll by the edges of the most outwardly positioned layers of the paper strip forming the roll, thereby also holding the outer layers of the supply roll in alignment with the supply roll as the supply roll rotates, a rotatably mounted folding roll having a flat bottomed annular groove therein with a width less than the unfolded width of the paper strip on said supply roll, guide means to continuously guide the paper strip from said supply roll a partial wrap around said folding roll, tension means to draw said paper strip firmly into the bottom of said annular groove in said folding roll,

thereby causing the paper strip to fold upon itself while taking the partial wrap around said roll, and means to crease the paper strip in its folded configuration.

14. Apparatus for continuously forming fiat, twistless folded paper yarn from a paper strip comprising: a supply roll of paper strip, means rotatably and vertically mounting said supply roll of paper strip for tangential unwinding, said means including a plurality of rotatable rolls for supporting and guiding said supply roll at spaced points along its periphery, at least one of said supporting and guiding rolls being positioned to engage the upper portion of said supply roll of paper and being slidably mounted to maintain peripheral contact with the roll of paper as it diminishes in size upon unwinding, a rotatably mounted folding roll having a flat bottom annular groove therein with a width less than the unfolded Width of the paper strip on said supply roll, guide means to continuously guide the paper strip from said supply roll a partial wrap around said folding roll, tension means to draw said paper strip firmly into the bottom of said annular groove in said folding roll, thereby causing the paper strip to fold upon itself while taking the partial wrap around said roll, and means to crease the paper strip in its folded configuration.

15. Apparatus according to claim 14- wherein the upper portion engaging the supporting and guiding roll is weighted to produce the desired degree of tension in the paper strip during the folding operation.

References Cited by the Examiner UNITED STATES PATENTS 594,586 11/97 Adams et al 270-93 1,201,804 10/16 Claviez 270-94 1,219,958 3/17 Kron 28-1 1,739,398 12/29 Iordhoy 270-66 1,943,438 1/ 34 Hopkinson 28-72 2,061,286 11/ 36 Millett 270-94 X 2,128,664 8/38 Sackner et al 139-1 2,213,242 9/40 Drew 93-84 2,284,321 5/42 Kimball 57-32 2,350,027 5/ 44 Gardner 28-72 2,499,463 3/ Cra-ry 93-84 X 2,654,936 10/53 Slovin 28-1 2,687,299 8/54 Kimball 93-84 X 2,896,297 7/59 Steen 57-154 2,911,214 11/59 Sherbrook 270-94 3,122,873 3/64 Lancaster et al 57-32 DONALD W. PARKER, Primary Examiner.

MERVIN STEIN, Examiner. 

1. APPARATUS FOR CONTINUOUSLY FORMING FLAT, TWISTLESS FOLDED PAPER YARN FROM A PAPER STRIP COMPRISING: A FIRST ROTATABLY MOUNTED ROLL HAVING A CURVED BOTTOMED ANNULAR GROOVE IN ITS PERIPHERAL SURFACE TO SHAPE THE UNFOLDED PAPER STRIP INTO A SUBSTANTIALLY U-SHAPED CONFIGURATION, A SECOND ROTATABLY MOUNTED ROLL HAVING A FLAT BOTTOMED ANNULAR GROOVE THEREIN WITH A WIDTH LESS THAN THE UNFOLDED WIDTH OF THE PAPER STRIP, GUIDE MEANS TO CONTINUOUSLY SUPPLY SAID PAPER STRIP TO SAID FIRST ROLL TO SHAPE SAID PAPER STRIP INTO A SUBSTANTIALLY U-SHAPED CONFIGURATION AND THEN TO GUIDE THE PAPER STRIP A PARTIAL WRAP AROUND SAID SECOND ROLL, TENSION MEANS TO DRAW THE SUBSTANTIALLY U-SHAPED PAPER STRIP FIRMLY INTO THE BOTTOM OF THE GROOVE IN SAID SECOND ROLL, THEREBY CAUSING THE EDGES OF THE PAPER STRIP TO FOLD INWARDLY TOWARD EACH OTHER ON THE SAME SIDE OF THE PAPER STRIP AS THE PAPER STRIP TAKES THE PARTIAL WRAP AROUND 